Corner connector

ABSTRACT

A corner connector device has outside and inside connector components each having a length. The outside component has first and second legs integrally connected along a lengthwise seam. The outside connecter component has an outside connector that extends lengthwise along the seam and projects from an outside surface. The inside connector component has third and fourth legs integrally connected along a lengthwise seam. The inside connector component has an inside connector that extends along the seam and projects from an inside surface. The inside and outside connectors can be lengthwise connected to and disconnected from one another with surfaces of the connector components spaced a distance from one another. Panels meeting at a corner can be captured between the spaced surfaces of the two connector components.

BACKGROUND

1. Field of the Disclosure

The present disclosure is generally directed to connectors for mountingwall and ceiling panels and tiles, and more particularly to cornerconnectors for mounting and joining such panels where they meet in twodifferent planes at a corner.

2. Description of Related Art

A number of devices and systems are known in the art that mount andsupport suspended or dropped ceiling panels, ceiling tiles, acousticaltiles, wall panels, or the like. These devices generally are configuredhaving distinctive features that are specific to a particular panelstructure or application. Once installed, most known devices and systemsare difficult to disassemble or make it difficult to remove and replaceindividual panels. Some prior art devices have parts that fasten to eachother and/or to other components to support a panel. This can make itdifficult or impossible to disassemble, uninstall, and reuse the parts.

Often, walls or ceilings have obstructions that are displaced from theplane of the surface. These often include water pipes, steam pipes,electrical conduit, air ducts, and the like. Known panel mountingsystems and devices are not configured to accommodate such structuresand obstacles. The obstructions are typically enclosed usingnon-removable materials such as sheetrock, panel-board or plywood.Sometimes, permanent grid systems can be cut, shaped, and riveted orfastened in place in a manner to mount panels that enclose theobstruction. However, the systems and components are difficult toinstall in such a manner, and make it time consuming to do so.

In some cases, the fastening mechanisms employ a male and a femalesection or compatible sections that connect to one another without theuse of fasteners. Typical prior known devices of this type are designedto suspend or mount ceiling or wall panels within in a single plane suchas on a flat ceiling or a flat wall.

U.S. Pat. No. 5,791,810 (Williams) discloses a detachable panel supportdevice for two-dimensional or flat, single plane applications. Inparticular, the Williams connector has a first connector section and asecond connector section, each with extending elements protruding fromthe section. The extending elements of the two sections join together orinterlock with one another and create spaces between the joined sectionsto capture panels. The Williams connecting device can form a reusableand continuous joint along each pair of mated sections to supportpanels. However, the Williams device is applicable to flat ortwo-dimensional walls or ceilings. U.S. Pat. No. 6,205,732 B1 (Rebman)describes a grid system for mounting and supporting ceiling tiles in atwo-dimensional suspended or dropped ceiling. The parts of the gridsystem snap together with male and female components.

Other connecting devices in the prior art are known that can accommodatea specific corner application to connect adjacent panels at a corner.For example, U.S. Pat. No. 5,676,486 (Keith) discloses a one-piececorner connector configured to join panels at an interior corner, i.e.,a 90° corner. The Keith device is formed as a one piece structureconfigured to join side edges of two rectangular panels that meet in acorner and is sized for panels of a specific thickness.

U.S. Pat. No. 5,065,559 (Zegel et al.) discloses a two-dimensional wallsystem with locking connectors and vertical supports. Panels are mountedvia fasteners to the supports. The corner pieces of the Zegel et al.system are internal to the corner and the panels fasten to an exteriorsurface of the pieces.

Other prior art connectors attempt to solve the problem of economicallyjoining panel supports at corners and yet maintaining an estheticallypleasing look. U.S. Pat. No. 6,094,879 (Dickeduisberg) describes aresilient corner configured to join two adjacent L-shaped channels endto end at an angle. The connectors are separate from the channels. U.S.Pat. No. 4,027,452 (Donnell) discloses an interior molding to join wallpaneling at an interior corner. The molding is a single unitary devicesecured to the walls in the corner and is sized to accept a specificpanel thickness.

U.S. Pat. No. 6,209,275 B1 (Cates et al.) discloses a wall system. Cateshas corner pieces that are configured to mate with panels specific tothe system. The Cates device requires numerous components and would becomplex to install and assemble. U.S. Pat. No. 4,555,255 (Kissel)describes an invertible corner-connecting clip which fits a right orleft-hand corner.

Additional interlocking connecting structures are also known in the artto included projecting and interlocking elements. U.S. Pat. No.6,217,251 B1 (Kato et al.) describes a joining device for connecting toelements end to end. An additional third hollow joint attaches over thejoined ends to retain the connection. U.S. Pat. No. 5,614,232 (Torigoeet al.) discloses an apparatus for producing a fastener withinterlocking projections.

SUMMARY OF THE DISCLOSURE

The present invention is for a corner connector structure or device thatemploys two elongate connecting components or strips that can supportceiling panels, ceiling tiles, acoustic tiles, wall panels, or the likeat virtually any type of corner. The disclosed device includes an insidecorner strip and an outside corner strip that can be connected with oneanother. When connected, the strips create spaces between the two stripsto capture, retain, and support a tile, panel, or the like. The insideand outside corner strips have extending connecting flanges that fittogether to join the strips. The present device is configured so as topermit the inside and outside strips to be easily engaged or assembledand disengaged or disassembled. Furthermore, the connecting flanges areconfigured to permit adjustment of the panel space so as to accommodatepanels of different thicknesses.

In the present example, the corner connector device comprises an outsideconnector component and an inside connector component. The outsidecomponent has a length and, when viewed in cross-section, a first legand a second leg. The first leg integrally connects to the second legalong a lengthwise seam and forms a channel. The first and second legseach have an inside surface oriented relative to one another at an angleW of less than 180 degrees and an outside surface oriented relative toone another at an angle X of more than 180 degrees. The outsidecomponent also has an outside connector that extends lengthwise alongthe outside component parallel to the seam and projects from one of theoutside surfaces. The inside connector component has a length and, whenviewed in cross section, a third leg and a fourth leg. The third legintegrally connects to the fourth leg along a lengthwise seam and formsa channel. The third and fourth legs each have an inside surfaceoriented relative to one another at an angle Y of less than 180 degreesand an outside surface oriented relative to one another at an angle Z ofmore than 180 degrees. The inside component also has an inside connectorthat extends lengthwise along the inside component parallel to the seamand projecting from one of the inside surfaces. The inside and outsideconnectors can be lengthwise selectively connected to and disconnectedfrom one another with confronting parts of the outside surfaces of theoutside connector component and inside surfaces of the inside connectorcomponent spaced a distance from one another.

In one embodiment, the outside connector has a pair of outside connectorflanges that are lengthwise spaced apart, and the inside connector hasan inside connector flange that interferingly fits between the pair ofoutside connector flanges when the inside and outside connectors areconnected.

In one embodiment, the inside connector has a pair of inside connectorflanges that are lengthwise spaced apart, and one outside connectorflange that interferingly fits between the pair of inside connectorflanges when the inside and outside connectors are connected.

In one embodiment, each of the outside and inside connector flanges hasa stem section connected to the respective outside and inside connectorcomponent and has a head extending along a free edge of the stemsection, and each head has a thickness that is greater than a thicknessof the corresponding stem section.

In one embodiment, a spacing between a pair of outside connector flangesmatches the head thickness of an inside connector flange.

In one embodiment, each head has a rounded tip and ramps that transitionfrom sides of the head to adjacent side surfaces of a corresponding stemsection.

In one embodiment, the angles W and Y are about 90° and the angles X andZ are about 270° on each of the respective inside and outside connectorcomponents.

In one embodiment, the outside connector component has a fastener grooveextending lengthwise along each of the outside surfaces of the first andsecond legs and the inside connector component has a fastener grooveextending lengthwise along each of the inside surfaces of the third andfourth legs.

In one embodiment, the inside surfaces of the first and second legs onthe outside connector component are mounted to an exposed, outer cornerof a structure with an angle of more than 180 degrees, and the insideconnector component is connected to the outside connector component.

In one embodiment, the outside surfaces of the third and fourth legs onthe inside connector component are mounted to an exposed, inner cornerof a structure with an angle of less than 180 degrees, and the outsideconnector component is connected to the inside connector component.

In one embodiment, the inside connector has a pair of inside connectorflanges that are lengthwise spaced apart, and the outside connector hasat least one outside connector flange that interferingly fits betweenthe pair of inside connector flanges when the inside and outsideconnectors are connected.

In one embodiment, a panel structure is captured between the outsidesurface of the first leg and the inside surface of the third leg, andanother panel structure is captured between the outside surface of thesecond leg and the inside surface of the fourth leg.

In one embodiment, each of the inside and outside connector flanges hasa stem section connected to the respective inside and outside connectorcomponent and a head extending along a free edge of the stem section.Each head can further have a thickness that is greater than a thicknessof the corresponding stem section.

In one embodiment, the outside connector can have three outsideconnector flanges that are lengthwise spaced apart, and an insideconnector flange can interferingly fit between adjacent ones of thethree outside connector components.

In one embodiment, the inside connector can have three inside connectorflanges that are lengthwise spaced apart, and an outside connectorflange can interferingly fit between adjacent ones of the three insideconnector flanges.

In one embodiment, the distance between confronting parts of the outsidesurfaces of the outside connector component and inside surfaces of theinside connector component can be adjusted between a minimum panelthickness and a maximum panel thickness position.

In other embodiments, panels of various materials can be mounted usingthe disclosed connector devices to cover beams, ducts, or piping in anesthetic, economical, three-dimensional manner. The disclosed connectordevices can support loads along inside and outside corners and can beadapted to cover other three-dimensional structures.

The outside and inside connector components of the disclosed cornerconnector device can be extruded from PVC. In addition, the cornerconnector device can be manufactured in a wide variety of othermaterials, depending on the suitability of a material to a particularuse. Other features and advantages of the corner connector andcomponents are illustrated in more detail in the attached figures anddetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present invention will becomeapparent upon reading the following description in conjunction with thedrawing figures, in which:

FIG. 1 shows a perspective, lengthwise fragmentary view of one exampleof a corner connector device according to the teachings of the presentinvention with the two connector strips disconnected.

FIG. 2 shows an end view of the disconnected device in FIG. 1.

FIG. 3 shows the device of FIG. 2 in an assembled condition with the twoconnector strips connected to one another and expanded to a maximumpanel space condition.

FIG. 4 shows an end view of the assembled device in FIG. 3 with theconnector strips in a minimum panel space condition and with panelscaptured between the connector strips.

FIG. 5 shows an end view of the disconnected strips in FIG. 2 andfasteners for optionally mounting either one or the other of the stripsto a corner.

FIG. 6 shows a cross section view of the assembled device in FIG. 5 andmounted to an outside or exterior corner.

FIG. 7 shows a cross section view of the assembled device in FIG. 5 andmounted to an inside or interior corner.

FIG. 8 shows a perspective view of the installed device in FIG. 7.

FIG. 9 shows a fragmentary end view of a combination of the devices inFIGS. 6 and 7 mounted to circumvent an exterior or outside corner and anadjacent interior or inside corner.

FIG. 10 shows a perspective view of the device and panel arrangement inFIG. 9.

FIG. 11 shows a cross section of multiple assembled devices in FIGS. 6and 7 configured to accommodate an obstruction displaced from a flatwall or ceiling.

FIG. 12 shows an end view of an alternative example of a cornerconnector device according to the teachings of the present invention.

FIG. 13 shows an end view of another alternative example of a cornerconnector device according to the teachings of the present invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

The disclosed corner connector devices represent an advance over priorart devices. The devices provide a corner connector to join and supportpanels at corners between two room walls, between a ceiling and a wall,or between other non-coplanar surfaces. The disclose devices employ twoconnector components or strips that can be connected to one anotherwithout the need for additional fasteners or separate parts, other thanthe two connector strips. Also, the disclosed devices can be assembledand installed in a manner that can accommodate both an interior orinside corner and an exterior or outside corner where two non-coplanarsurfaces meet at a corner. In addition to being capable of more than oneinstallation orientation, the disclosed devices have a simple,straightforward design, are easy to assemble and install, and arerelatively simple and economical to manufacture. The disclosed devicessolve a long-felt need for a system that can easily and readily joinpanels at corners. The disclosed devices also solve a long-felt need fora system that can be configured to enclose beams, pipes, ducts, columns,and similar structures, obstructions, and the like. Wall and ceilingpanels and tiles, once mounted using the disclosed devices, are easy toremove, reinstall, replace, swap, and the like. One of the two connectorstrips can easily be removed from the other to release a panel capturedbetween the two connectors.

Turning now to the drawings, FIGS. 1 and 2 illustrate one example of aconnector device in accordance with the teachings of the presentinvention. In this example, the device is disclosed for use on or incorners that have surfaces meeting at right angles. In this example, theconnector device has two elongate connector components or strips 10 and12 that can be cut or trimmed to a desired length. The two strips 10 and12 can also removably connect to one another and each strip can bemounted to a surface or supporting structure, depending on theapplication.

The first connector strip 10 in FIGS. 1 and 2 is configured to fit overan outside corner and hereinafter is called an outside connector strip.The outside connector strip 10 is essentially an elongate generally L-or V-shaped channel when viewed in cross section or on end. The channelis defined by a first leg 14 and a second leg 16 that are joined orconnected to one another at a joint or seam 18. In this example, avalley or trough T1 of the seam 18 is created at the juncture betweeninner facing surfaces 20 and 21 of the respective first and second legs14 and 16. Similarly, a peak or apex A1 of the seam 18 is created at thejuncture between outer facing surfaces 22 and 23 of the respective firstand second legs 14 and 16.

As noted above, the legs 14 and 16 can be oriented at a 90° or rightangle relative to one another. In this example, the 90° angle W iscreated between the inner facing surfaces 20 and 21 of the legs 14 and16. As a result, a 270° angle X is created between the outer facingsurfaces 22 and 23 of the legs 14 and 16 in this example. Depending onthe particular application, it is within the scope and spirit of theinvention for the channel angle of the outside connector strip 10 to begreater than or less than 90°, if desired. In any event, the innerfacing surfaces will define an angle W less than 180° and the outerfacing surfaces will define an angle X greater than 180°. Outsideconnector strips having other angles can be manufactured for panelinstallations requiring specific needs, such as joining wall and ceilingpanels where the room walls meet a vaulted ceiling. However, as is knownin the construction and architectural fields, a majority of wall andceiling structures are formed with right angle surfaces between wall,ceiling, and/or obstruction surfaces.

Also as shown in FIGS. 1 and 2, the outside connector strip 10 has anoutside connector that projects from part of the channel to connect tothe other strip 12. In this example, the outside connector includes aplurality of connector flanges that are spaced apart from one another.In this example, the plurality of flanges includes a first outsideconnector flange 26 and a second outside connector flange 28. As willbecome evident to those of ordinary skill in the art upon reading thisdisclosure, more than two outside projecting elements or flanges can beused within the teachings of the present invention. However, in thedisclosed example a minimum of two of the connector flanges 26 and 28 isprovided in order to connect the strip 10 with the strip 12 as describedbelow. Also, the positioning of the outside flanges may vary from thepositions as shown.

Each outside connector flange 26 and 28 has a respective first stemsection 30 and second stem section 32 that is attached to the channel.In this example, the stem section 30 of the flange 26 extends from theoutside surface 22 of the first leg 14 and is offset a distance from theapex A1 along the surface. The stem section 32 of the flange 28 extendsfrom the outside surface 23 of the second leg 16 very near, but slightlyoffset from, the apex A1. Each connector flange 26 and 28 is somewhatpaddle-shaped and has a respective bead or head section 34 and 36 on thefree edge of the corresponding stem 30 and 32. The heads 34 and 36 havea greater thickness than the stems 30 and 32. Thus, a gap G1 between theadjacent heads 34 and 36 is smaller than a spacing or distance S1between the adjacent stems 30 and 32.

In this example, the connector flanges 26 and 28 are oriented parallelwith one another and are oriented at 135° obtuse angles relative totheir adjacent legs surface 22 and 23. Thus, the flanges essentiallybisect the 270° angle X between the outer facing surfaces 22 and 23 inthis example. As needed, the flange angles can also change, if thechannel/leg angle is changed to accommodate a particular non-right angleinstallation application. Additionally, the flanges need not be orientedto bisect the obtuse angle as shown. Also as represented in FIG. 1, thefirst and second outside connector flanges 26 and 28 extend continuouslylengthwise along the channel, as do the first and second legs 14 and 16.The length of the flanges 26 and 28 can be trimmed as the outsideconnector strip 10 is trimmed to a desired length during installation.

The second corner connector strip 12 in FIGS. 1 and 2 is configured tofit within and inside corner and hereinafter is called an insideconnector strip. The inside connector strip 12 is also essentially anelongate channel that is generally L- or V-shaped when viewed in crosssection or on end. The channel is defined by a third leg 50 and a fourthleg 52 that are joined or connected to one another at a joint or seam54. In this example, a valley or trough T2 of the seam 54 is created atthe juncture between inner facing surfaces 55 and 56 of the respectivethird and fourth legs 50 and 52. Similarly, a peak or apex A2 of theseam 54 is created at the juncture between outer facing surfaces 57 and58 of the respective third and fourth legs 50 and 52.

As with the strip 10, the legs 50 and 52 can be oriented at a 90° orright angle relative to one another. In this example, the 90° angle Y iscreated between the inner facing surfaces 55 and 56 of the legs 50 and52. As a result, a 270° angle Z is created between the outer facingsurfaces 57 and 58 of the legs 50 and 52 in this example. Depending onthe particular application, it is within the scope and spirit of theinvention for the channel angle of the inside connector strip 12 to begreater than or less than 90°, if desired. In any event, the innerfacing surfaces will define an acute angle Y less than 180° and theouter facing surfaces will define an angle Z greater than 180°. Insideconnector strips having other angles can be manufactured for panelinstallations requiring specific needs, such as joining wall and ceilingpanels where the room walls meet a vaulted ceiling, as noted above.

As further shown in FIGS. 1 and 2, the inside connector strip 12 has aninside connector that projects from part of the channel to connect tothe other strip 10. In this example, the inside connector includes aplurality of inside connector flanges that project from part of thechannel and that are spaced apart from one another. In this example, theplurality of flanges includes a third inside connector flange 60 and afourth inside connector flange 62. As will become evident to those ofordinary skill in the art upon reading this disclosure, more than twoinside projecting elements or flanges can be used within the teachingsof the present invention. However, in the disclosed example a minimum oftwo of the inside connector flanges 60 and 62 are provided in order toconnect the strip 12 with the strip 10 as described below. In onealternative example, one of the two connector strips 10, 12 could beprovided with only a single flange that connects with a pair of theflanges on the other strip. Also, the positioning of the flanges on thestrip 12 may vary from the positions as shown.

Each inside connector flange 60 and 62 has a respective third stemsection 70 and fourth stem section 72 that is attached to the channel.In this example, the stem section 70 of the flange 60 extends from theinside surface 55 of the third leg 50 very near, but slightly offsetfrom, the apex A2. The stem section 72 of the flange 62 extends from theinside surface 56 of the fourth leg 52 and is offset a distance from theapex A2 along the surface. Each connector flange 60 and 62 is alsosomewhat paddle-shaped and has a respective bead or head section 74 and76 on the free edge of the corresponding stem 70 and 72. The heads 74and 76 have a greater thickness than the stems 70 and 72. Thus, a gap G2between the adjacent heads 74 and 76 is smaller than a spacing ordistance S2 between the adjacent stems 70 and 72.

As discussed in greater detail below, the sizes, shapes, spacing, andgap of the first and second outside flanges 26 and 28 match the sizes,shapes, spacing, and gap of the third and fourth flanges 60 and 62. Inthis example, the connector flanges 60 and 62 are also oriented parallelwith one another. However, the inside connector flanges 60 and 62 areoriented at 45° acute angles relative to their adjacent legs surface 55and 56. Thus, the flanges essentially bisect the acute 45° angle betweenthe outer facing surfaces 55 and 56 in this example. As with the strip10, the flange angles can also change, if the channel/leg angle of theinside connector strip 12 is changed to accommodate a particularnon-right angle installation application. Also, the flanges need not beoriented to bisect the acute angle as shown. The third and fourth insideconnector flanges 60 and 62 also extend continuously lengthwise alongthe channel, as do the third and fourth legs 50 and 52. The length ofthe flanges 60 and 62 can be trimmed as the inside connector strip 12 istrimmed to a desired length during installation.

As shown in FIG. 2, the connector strips 10 and 12 can be connected toone another by pushing the inside connector flanges 26, 28 toward theoutside connector flanges 60 and 62 together in the direction of ArrowC. Similarly, the strips 10 and 12 can be disconnected from one anotherby pulling their respective flanges apart in the direction of the ArrowD. To facilitate connection in the Arrow C direction, each bead or head34, 36, 74, 76 has a rounded end or tip 80. To facilitate disconnectionin the Arrow D direction, each bead or head 34, 36, 74, 76 has ramps 82that provide angled transition surfaces between the thicker heads andthe respective thinner stem sections 30, 32, 70, 72 as discussed furtherbelow. The flanges 26, 28, 60, 62 are resiliently flexible such thateach pair can be moved or displaced apart.

Referring now to FIG. 3, the inside and outside connector strips 10, 12are shown connected to one another. In this example, the positioning ofthe connector flanges 26 and 28 relative to the apex A1 on the outsidestrip 10 is offset in the opposite direction to the positioning of theconnector flanges 60 and 62 relative to the apex A2 on the insideconnector strip 12. This offset differential aligns or centers the twoconnector strips 10, 12 relative to one another when connected. In thedisclosed example, the head or bead 36 of the outside connector flange28 is positioned between the heads 74, 76 of the inside connectorflanges 60, 62. The head or bead 74 of the inside connector flange 60 islikewise positioned between the heads 34, 36 of the outside connectorflanges 26, 28. As the two strips 10, 12 are pushed together, therounded tips 80 of the heads 36 and 74 push between the flanges 60, 62and 26, 28, respectively, to pass through the gaps G2 and G1 as shown inFIG. 2. The heads 36 and 74 will then seat in the spaces S2, S1 betweenthe opposing pair of flanges after passing beyond the correspondingheads.

In this example, the spaces S1 and S2 are sized to essentially match thethickness of the heads. The head and space size, along with theresiliency of the flanges 26, 28, 60, and 62, allows the flanges toreturn to their essentially parallel orientations once the strips 10 and12 are connected. In FIG. 3, the two connector strips 10 and 12 aredepicted in a position just after the heads 76 and 34 have seated in theflange spaces S1 and S2. This position defines a maximum panel thicknessposition for the connector device. If the two strips 10 and 12 arepulled apart beyond this maximum position, the heads 34 and 76 willreturn through the gaps G2, G1 and the strips will separate. Once in themaximum position, the two strips 10 and 12 can also be pushed furthertogether until one of the heads bottoms out against the opposite strip.This bottomed out position defines a minimum panel thickness positionfor the connector device.

In this example, the head 34 of flange 26 bottoms out when in a minimumposition. Nonetheless, the length of the flanges could vary, and, if ofsufficient length, one or the other of flanges 60, 62 could bottom out.Furthermore, the two connector strips 10, 12 could be connected in anon-align position, wherein, for example, the head 34 of flange 26 couldbe seated between flanges 60, 62, provided that the legs are ofsufficient length to capture and support a panel.

In this example, the corner connector device including the connectorstrips 10 and 12 are intended for installation of panels such as ceilingpanels or tiles, wall panels, and the like. The spacing between theconnector strips 10 and 12 so that they can be positioned relative toone another anywhere between the maximum and minimum panel thicknesspositions. This can be done to accommodate different sized panels. Also,in many situations it may be impracticable to have two tightly connectedstrips. Many building structures and building materials, includingceiling tiles and wall and ceiling panels, have dimensionalirregularities. The positional adjustment capability between theconnector strips 10 and 12 of the disclosed connector device canaccommodate such irregularities.

Referring now to the configuration in FIG. 4, panels 84 and 86 are showncaptured by the engaged connected strips 10 and 12 of FIG. 3. The panel84 is captured between the outside surface 22 of the leg 14 on theoutside connector strip 10 and the inside surface 55 of the leg 50 onthe inside connector strip 12. These surfaces 22, 55, and thus the legs14, 50, at least partly confront or overlie one another to capture bothsides of the panel. Similarly, the panel 86 is captured between theoutside surface 23 of the leg 16 on the outside connector strip 10 andthe inside surface 56 of the leg 52 on the inside connector strip 12.These surfaces 23, 56, and thus the legs 16, 52, at least partlyconfront or overlie one another to capture both sides of the panel 86.

The spacing between the confronting surfaces 22, 55 and 23, 56 can beadjusted between the maximum and minimum panel thickness positions asnoted above so as to adjust to the panel thickness and to snugly capturethe panels, if desired. The term panel is used herein for planar ceilingtiles and wall and ceiling panels, such as the panels 84 and 86.However, it is certainly within the spirit and scope of the presentinvention that the connector devices support other objects that have aperimeter edge capable of being captured and supported by the strips 10and 12. Such objects can include artwork, posters, decorative panels,surface relief tiles, or other three-dimensional objects. The term“panel” as used herein is intended to encompass such other objects andthe connector device is intended to be capable of supporting such otherobjects or “panel-like loads.”

As will be evident to those having ordinary skill in the art, thedimensions for the various parts of the connector device can vary andyet fall within the spirit and scope of the present invention. Thematerial thickness of the legs and flanges can be varied to alter theload supporting capability of the connector device and the forcenecessary to connect and disconnect the two strips 10 and 12 of thedevice. Width of the flanges and legs can also be varied for the samepurpose. Also, the various dimensions can be altered to accommodatedifferent thickness panels or tiles. Additionally, the dimensions can bedesigned so that a specific connector device can have a desired rangebetween the minimum and maximum panel thickness position to accommodatea desired range of panel thicknesses. As used herein, the term length isused to represent the lengthwise dimension along the longitudinal axisof the devices. The length of the strips or components and thus thevarious parts of these strips can vary considerably. The otherdimensions of the strips can be altered to significantly change thefunctional characteristics of the disclosed devices.

In one example, each head 34, 36, 74, 76 can have a material thicknessof approximately 0.095 inches. In one example, each connector flange 26,28 of the strip 10 can have a width, measured from about the middle ofthe seam 18 to the head tips 80, of approximately 1.75 inches. In oneexample, each connector flange 60 and 62 of the strip 12 can also have awidth, measured from about the middle of the seam 54 to the head tips80, of approximately 1.768 inches. In one example, each bead or head 34,36, 74, 76 can have a width from the tip 80 to the end of each ramp 82of approximately 0.211 inches. In one example, each stem section 30, 32,70, 72 of the connector flanges 26, 28, 60, 62 can have a materialthickness of approximately 0.07 inches. Each of the legs 14, 16, 50, 52of each channel has an outer edge 90, 92, 94, 96, respectively. In oneexample, each leg 14, 16, 50, 52 can have a width from the respectiveapex A1 or A2 to the corresponding outer edge 90, 92, 94, 96 ofapproximately 2.0 inches. In one example, each leg 14, 16, 50, 52 canalso have a material thickness of approximately 0.08 inches. The gapdimensions G1 and G2 in one example can be approximately 0.030 inches.The spacing dimensions S1 and S2 in one example can be approximately0.095 inches, which matches the thickness of the heads. When the spacingdimensions S1 and S2 matches the thickness of the heads 34, 36, 74, 76,the heads 34, 36, 74, 76 fit snugly between the stem sections 30, 32,70, 72 of the flanges 26, 28, 60, 62. By fitting snugly, the connectionbetween the two connector strips 10, 12 is frictionally maintained atthe ideal dimension to support a panel of a given thickness that isbetween a maximum panel thickness and a minimum panel thickness.

Each connector strip also has continuous fastener grooves to assist ininstallation of the connector device. As shown in FIGS. 1-3 and 5, theoutside connector strip 10 has fastener grooves 100, 102 formedlengthwise along the outside surfaces 22, 23 on the first and secondlegs 14, 16, respectively. Similarly, the inside connector strip 12 hasfastener grooves 104, 106 formed lengthwise along the inside surfaces55, 56 on the third and fourth legs 50, 52, respectively. As representedin FIG. 5, conventional screws 108 or other fasteners can be alignedwith one of the grooves anywhere along the length of the connectordevice. The grooves will help assist one in properly positioning and inholding the fastener in position during installation.

Because the grooves are continuous in this example, an installer caninstall the connector device using any number of fasteners desired andat virtually any location along the length of the device, as needed.This can allow the device to support a relatively heavy panel load ifneeded and can minimize product waste caused by trimming duringinstallation. An installer can place screws 108 at intervals along thelongitudinal length of the grooves 100, 102, 104, 106, as necessary. Forexample, structural elements such as wall studs, furring strips, andfloor or ceiling joists are very often found at regular 16 inchcenter-to-center intervals. However, typical center intervals can rangefrom less than 16 inches to 24 inches and more. The disclosed connectordevices can accommodate virtually any installation application.

In addition, virtually any type of fastener can be utilized to installthe disclosed connector devices. In one example, the screws 108 can be adrywall, self-tapping fastener, which are well known and available atnearly any building materials outlet or hardware store. Drywall screwshave been shown to penetrate plastic materials such as polyvinylchloride(PVC) without cracking the plastic. The disclosed connector strips canalso be fabricated from a variety of materials and processes, as long asthe connector flanges have some resiliency and flexibility forconnection and disconnection and the device is capable of adequatelysupporting loads, as desired. In one example, the connector strips 10and 12 can be formed having a fire retardant characteristic, even ifformed from a plastic material, which can yield an important marketingadvantage.

In one example, the strips 10 and 12 can be continuously extruded fromPVC or other suitable plastic materials. The devices can be trimmed uponextrusion to desired lengths for commercial sale and shipping and thenfurther trimmed by an installer on the job as needed. In other examples,the connector strips 10 and 12 can be formed of wood, metal, paper,paperboard, cardboard, rubber, and the like. Fibrous composites such asKevlar or fiberglass are also perhaps suitable. However, PVC can beeconomically extruded into the disclosed shapes by plastics fabricatorsthat are skilled in the art of plastic extrusions. A continuous andappropriately sized and shaped connector strip can then be trimmed tostandard or custom lengths.

In one example illustrated in FIG. 6, the connector device as depictedin FIG. 4 can be mounted to create an outside corner joint betweenadjacent panels 84 and 86. In this example, an installer would trim tolength an outside corner strip 10. The installer then would place thetrimmed strip 10 with the trough T1 facing an exposed outer corner 120of a structural object 122, such as a stud in this example. The strip'sinside surface 20 of the leg 14 abuts a surface 124 of the stud 122 andthe inside surface 21 of the leg 16 abuts a surface 126 of the stud.Fasteners 108 are then installed through the grooves 100 and 102 tosecure the trimmed strip in place on the stud 122 (See FIG. 5). Thepanels 84 and 86 can then be positioned against the respective exposedoutside leg surfaces 22 and 23. The inside connector strip 12 can thenbe connected to the strip 10 as discussed above to capture the panels inplace. The outside corner arrangement in FIG. 6 can represent either avertical wall corner or a horizontal ceiling structure corner.

In another example illustrated in FIGS. 7 and 8, the connector device asdepicted in FIG. 4 can also be mounted to create an inside corner jointbetween adjacent panels 84 and 86. In this example, an installer wouldtrim to length an inside corner strip 12. The installer then would placethe trimmed strip 12 with the apex A2 facing an exposed inner corner 130of a structural object, such as adjoining studs 132, 133 in thisexample. The strip's outside surface 57 of the leg 50 abuts a surface134 of the stud 132 and the outside surface 58 of the leg 52 abuts asurface 136 of the stud 133. Fasteners 108 are then installed throughthe grooves 104 and 106 to secure the trimmed strip 12 in place on thestuds 132, 133 (See FIG. 5). The panels 84 and 86 can then be positionedagainst the respective exposed inside leg surfaces 55, 56. The outsideconnector strip 10 can then be connected to the strip 12 as discussedabove to capture the panels in place. The inside corner arrangement inFIG. 7 can also represent either a vertical wall corner, a wall toceiling corner joint, or a horizontal ceiling structure corner.

In another example, FIGS. 9 and 10 illustrate a combination of thearrangements in FIGS. 6-8. This arrangement can be employed in ahorizontal orientation to enclose a kitchen or other type of soffit orto enclose one side of a ceiling obstruction such as an exposed water orsteam pipe or a beam. The opposite side of such an obstruction can beconfigured as a mirror image arrangement of the connector devices andpanels as seen in FIG. 11. These arrangements can also be employed in avertical orientation to enclose wall obstructions such as an exposedwater pipe or air duct. These embodiments could be used in varyingcombinations to conform to the corners formed by other structuralarrangements as well. In one example, four of the outside arrangementsshown in FIG. 6 can be employed to fully enclose a completely exposedheating duct or all sides of a support column in a basement or atticenvironment. The disclosed devices can be employed in the variousconfigurations to create a pleasing appearance within an office,recreational, or industrial area to hide structural features.

An alternative example of a connector device is shown in FIG. 12. Inthis example, the inside connector strip 12 is identical to thatdescribed previously with respect to FIGS. 1-11. The outside connectorstrip 200 shown in FIG. 12 is also nearly identical to the describedabove outside strip 10. However, in this example, the strip 200 includesa fifth connector flange 202 that has a head or bead 204 and a stemsection 206. In this example, the flanges 60 and 62 of the insideconnector strip each seat between a pair of the connector flanges 26,28, 200 when the strips 200 and 12 are connected in a manner asdescribed above.

FIG. 13 shows yet another alternative example of a connector device. Inthis example, the outside connector strip 10 is identical to thatdescribed previously with respect to FIGS. 1-11. In this example, theinside connector strip 210 has only the third connector flange 70. Thefourth connector flange 72 has been eliminated. In this example, thesingle flange 70 seats between the pair of flanges 26 and 28 when thestrips 10 and 210 are connected in a manner as described above.

The illustrated example in FIGS. 1-11 shows a pair of the connectorflanges on each strip 10 and 12. By having two flange pairs, each striphas one flange captured between the pair on the other strip and oneflange resiliently pressing against an outside of one of the flanges ofthe other pair. This mutual engaged flange arrangement can assist inmaintain a consistent force applied by each pair of flanges when thedevice is installed and the strips are connected. This also cansignificantly increase the force applied by the flanges both to resistdisconnection and during connection while permitting the materialthickness of any one flange, head, or the like to be relatively minimal.However, as depicted in FIGS. 12 and 13, other flange arrangements arecertainly possible. Either one of the components 10 or 12 can have onlya single flange, while the other has a pair of flanges. Either one ofthe components 10 or 12 can have three or more flanges while the othercomponent can have only two or more.

An important consideration in all embodiments is the degree offlexibility required to maintain the engagement of the extending flangesin their respective cavities. For example, metal and plastic cornerconnectors are well suited for ceiling or wall panel applications. As tomanufacturing requirements, a preferred standard length of each cornerconnector would be approximately eight feet per unit.

Load capacity depends upon the relationship between the flexibility ofthe material and the resistance to engagement (and disengagement)created by the number of connector flanges and/or the difference inthickness between stem sections and the heads. In other examples, theconnector flanges could also be replaced by other types of mechanismsfor the inside and outside connectors that permit connection anddisconnection of the two strips. The load capacity could be altereddepending on the connection mechanism utilized.

In general, the more flexible the material, the less the load which canbe supported. However a greater difference in thickness between thestems and paddle-shaped upper ends can compensate for a more flexiblematerial. If the paddle-shaped ends are relatively thicker than thestems 10, then the resistance to engagement or disengagement will begreater.

Although certain corner connector devices, systems, and methods havebeen described herein in accordance with the teachings of the presentdisclosure, the scope of coverage of this patent is not limited thereto.On the contrary, this patent covers all embodiments of the teachings ofthe disclosure that fairly fall within the scope of permissibleequivalents. It will be apparent to those of ordinary skill in the artthat changes, additions and/or deletions may be made to the disclosedexamples without departing from the spirit and scope of the invention.The foregoing description is given for clearness of understanding only,and no unnecessary limitations should be understood therefrom.Modifications within the scope of the invention may be apparent to thosehaving ordinary skill in the art.

1. A corner connector device and panel combination, the corner connectordevice forming a reusable corner joint to support two panels, thecombination comprising: (A) an outside connector component having alength and, when viewed in cross-section, comprising: (a) a first legand a second leg, the first leg integrally connected to the second legalong a lengthwise seam and forming a channel, the first and second legseach having an inside surface oriented relative to one another at anangle W of less than 180 degrees and each having an outside surfaceoriented relative to one another at an angle X of more than 180 degrees,and (b) an outside connector extending lengthwise along the outsideconnector component parallel to the seam and projecting from one of theoutside surfaces; (B) an inside connector component having a length and,when viewed in cross-section, comprising: (a) a third leg and a fourthleg, the third leg integrally connected to the fourth leg along alengthwise seam and forming a channel, the third and fourth legs eachhaving an inside surface oriented relative to one another at an angle Yof less than 180 degrees and each having an outside surface orientedrelative to one another at an angle Z of more than 180 degrees, and (b)an inside connector extending lengthwise along the inside connectorcomponent parallel to the seam and projecting from one of the insidesurfaces; and (C) two panel structures, wherein the inside and outsideconnectors can be lengthwise selectively connected to and disconnectedfrom one another with confronting parts of the outside surfaces of theoutside connector component and inside surfaces of the inside connectorcomponent spaced a distance from one another, wherein one of the insideand outside connectors has a pair of connector flanges that arelengthwise spaced apart, and wherein the other of the inside and outsideconnectors has a connector flange that interferingly fits between thepair of connector flanges when the inside and outside connectors areconnected, wherein the outside connector component has a fastener grooveextending lengthwise along each of the outside surfaces of the first andsecond legs, and wherein the inside connector component has a fastenergroove extending lengthwise along each of the inside surfaces of thethird and fourth legs, wherein the outside connector component can beoptionally and removably mounted to an outside corner of a structure viafasteners passing through the fastener grooves in the first and secondlegs and the inside connector component can be connected thereto, thetwo panel structures supported between the respective confronting partsof the first and third legs and the second and fourth legs forming anoutside paneled corner, and wherein the inside connector component canbe optionally and removably mounted to an inside corner of a structurevia fasteners passing through the fastener grooves in the third andfourth legs and the outside connector component can be connectedthereto, the two panel structures supported between the respectiveconfronting parts of the first and third legs and the second and fourthlegs forming an inside paneled corner.
 2. A corner connector device andpanel combination according to claim 1, wherein the outside connectorhas a pair of outside connector flanges that are lengthwise spacedapart, and wherein the inside connector has an inside connector flangethat interferingly fits between the pair of outside connector flangeswhen the inside and outside connectors are connected.
 3. A cornerconnector device and panel combination according to claim 2, wherein theinside connector has a pair of the inside connector flanges that arelengthwise spaced apart, and wherein one of the outside connectorflanges interferingly fits between the pair of inside connector flangeswhen the inside and outside connectors are connected.
 4. A cornerconnector device and panel combination according to claim 3, wherein theoutside connector has three of the outside connector flanges that arelengthwise spaced apart, and wherein each of the pair of insideconnector flanges interferingly fits between adjacent ones of the threeoutside connector components.
 5. A corner connector device and panelcombination according to claim 3, wherein the inside connector has threeof the inside connector flanges that are lengthwise spaced apart, andwherein each of the pair of outside connector flanges interferingly fitsbetween adjacent ones of the three inside connector flanges.
 6. A cornerconnector device and panel combination according to claim 2, whereineach of the outside and inside connector flanges has a stem sectionconnected to the respective outside and inside connector component andhas a head extending along a free edge of the stem section, and whereineach head has a thickness that is greater than a thickness of thecorresponding stem section.
 7. A corner connector device and panelcombination according to claim 6, wherein a spacing between the pair ofoutside connector flanges matches the head thickness of the insideconnector flange.
 8. A corner connector device and panel combinationaccording to claim 6, wherein each head has a rounded tip and ramps thattransition from sides of the head to adjacent side surfaces of thecorresponding stem section.
 9. A corner connector device and panelcombination according to claim 1, wherein the angles W and Y are about90° and the angles X and Z are about 270° on the respective inside andoutside connector components.
 10. A corner connector device and panelcombination according to claim 1, wherein the inside surfaces of thefirst and second legs on the outside connector component are mounted toan exposed, outer, obtuse angled corner of a structure, and wherein theinside connector component is connected to the outside connectorcomponent.
 11. A corner connector device and panel combination accordingto claim 10, wherein one of the two panel structures is captured betweenthe outside surface of the first leg and the inside surface of the thirdleg, and wherein the other of the two panel structures is capturedbetween the outside surface of the second leg and the inside surface ofthe fourth leg.
 12. A corner connector device and panel combinationaccording to claim 1, wherein the outside surfaces of the third andfourth legs on the inside connector component are mounted to an exposed,inner, acute angled corner of a structure, and wherein the outsideconnector component is connected to the inside connector component. 13.A corner connector device and panel combination according to claim 12,wherein one of the two panel structures is captured between the outsidesurface of the first leg and the inside surface of the third leg, andwherein the other of the two panel structures is captured between theoutside surface of the second leg and the inside surface of the fourthleg.
 14. A corner connector device and panel combination according toclaim 1, wherein the inside connector comprises a pair of insideconnector flanges that are lengthwise spaced apart, and wherein theoutside connector comprises at least one outside connector flange thatinterferingly fits between the pair of inside connector flanges when theinside and outside connectors are connected.
 15. A corner connectordevice and panel combination according to claim 14, wherein each of theinside and outside connector flanges has a stem section connected to therespective inside and outside connector component and a head extendingalong a free edge of the stem section, and wherein each head has athickness that is greater than a thickness of the corresponding stemsection.
 16. A corner connector device and panel combination accordingto claim 15, wherein a spacing between the pair of inside connectorflanges matches the head thickness of the outside connector flange. 17.A corner connector device and panel combination according to claim 15,wherein each head has a rounded tip and ramp that transition from thehead thickness to adjacent surfaces of the corresponding stem section.18. A corner connector device and panel combination according to claim1, wherein the distance between the confronting parts of the outsidesurfaces of the outside connector component and inside surfaces of theinside connector component can be adjusted between a minimum panelthickness and a maximum panel thickness position.
 19. A corner connectordevice and panel combination according to claim 1, wherein the outsideand inside connector components are extruded from PVC.
 20. A cornerconnector device and panel combination according to claim 1, wherein thefirst and second legs of the outside connector component are ofsubstantially the same construction as the third and fourth legs of theinside connector component.
 21. A corner connector device for supportingpanels at a corner of a structure, the corner connector devicecomprising: (A) an outside connector component having a length and, whenviewed in cross-section, comprising: (a) a first leg and a second leg,the first leg integrally connected to the second leg along a lengthwiseseam and forming a channel, the first and second legs each having aninside surface oriented relative to one another at an angle W of lessthan 180 degrees and each having an outside surface oriented relative toone another at an angle X of more than 180 degrees, and (b) an outsideconnector extending lengthwise along the outside connector componentparallel to the seam and projecting from one of the outside surfaces;and (B) an inside connector component having a length and, when viewedin cross-section, comprising: (a) a third leg and a fourth leg, thethird leg integrally connected to the fourth leg along a lengthwise seamand forming a channel, the third and fourth legs each having an insidesurface oriented relative to one another at an angle Y of less than 180degrees and each having an outside surface oriented relative to oneanother at an angle Z of more than 180 degrees, and (b) an insideconnector extending lengthwise along the inside connector componentparallel to the seam and projecting from one of the inside surfaces,wherein the inside and outside connectors can be lengthwise selectivelyconnected to and disconnected from one another with confronting parts ofthe outside surfaces of the outside connector component and insidesurfaces of the inside connector component spaced a distance from oneanother for supporting a panel structure between the respectiveconfronting parts of each of the first and third legs and the second andfourth legs, wherein one of the inside and outside connectors has a pairof connector flanges that are lengthwise spaced apart, and wherein theother of the inside and outside connectors has a connector flange thatinterferingly fits between the pair of connector flanges when the insideand outside connectors are connected, wherein the outside connectorcomponent has a fastener groove extending lengthwise along each of theoutside surfaces of the first and second legs, and wherein the insideconnector component has a fastener groove extending lengthwise alongeach of the inside surfaces of the third and fourth legs, wherein theoutside connector component can be optionally and removably mounted toan outside corner of a structure via fasteners passing through thefastener grooves in the first and second legs and the inside connectorcomponent can be connected thereto forming an outside corner joint, andwherein the inside connector component can be optionally and removablymounted to an inside corner of a structure via fasteners passing throughthe fastener grooves in the third and fourth legs and the outsideconnector component can be connected thereto forming an inside cornerjoint.
 22. A reusable joint device for supporting panels at a corner ofa structure, the joint device comprising: (A) an outside connectorcomponent having a length and, when viewed in cross-section, comprising:(a) a first leg and a second leg, the first leg integrally connected tothe second leg along a lengthwise seam and forming a channel, the firstand second legs each having an inside surface oriented relative to oneanother at an angle W of less than 180 degrees and each having anoutside surface oriented relative to one another at an angle X of morethan 180 degrees, and (b) an outside connector extending lengthwisealong the outside connector component parallel to the seam andprojecting from one of the outside surfaces; and (B) an inside connectorcomponent having a length and, when viewed in cross-section, comprising:(a) a third leg and a fourth leg, the third leg integrally connected tothe fourth leg along a lengthwise seam and forming a channel, the thirdand fourth legs each having an inside surface oriented relative to oneanother at an angle Y of less than 180 degrees and each having anoutside surface oriented relative to one another at an angle Z of morethan 180 degrees, and (b) an inside connector extending lengthwise alongthe inside connector component parallel to the seam and projecting fromone of the inside surfaces, wherein the inside and outside connectorscan be lengthwise selectively connected to and disconnected from oneanother with confronting parts of the outside surfaces of the outsideconnector component and inside surfaces of the inside connectorcomponent spaced a distance from one another for supporting a panelstructure between the respective confronting parts of each of the firstand third legs and the second and fourth legs, wherein one of the insideand outside connectors has a pair of connector flanges that arelengthwise spaced apart, and wherein the other of the inside and outsideconnectors has a connector flange that interferingly fits between thepair of connector flanges when the inside and outside connectors areconnected, wherein the outside connector component has a fastener grooveextending lengthwise along each of the outside surfaces of the first andsecond legs, and wherein the inside connector component has a fastenergroove extending lengthwise along each of the inside surfaces of thethird and fourth legs, wherein either one of the inside or outsideconnector components can be optionally and removably mounted to a cornerof a structure via fasteners passing through the fastener grooves ineither the third and fourth legs or the first and second legs,respectively, and the other of the outside or inside connectorcomponents can be connected thereto optionally forming either an insideor outside corner joint device, respectively, and wherein the jointdevice can be disconnected, removed from the corner, and reused tooptionally form either one of an inside or outside corner joint device.